1

chapter
Automation solution guide
From the needs, choose an architecture, then a technology to lead to a product

1. Automation solution Summary guide

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1.1 1.2 1.3 1.4 1.5 Introduction The automation equipment Automation architectures Architecture definition Choice of automated equipment
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1. Automation solution guide

1.1 Introduction

1.1 1.2

Introduction The automation equipment

Progress in industrial automation has helped industry to increase its productivity and lower its costs.Widespread use of electronics and powerful, flexible software have given rise to more efficient modular designs and new maintenance tools. Customer demands have also evolved substantially; competition, productivity and quality requirements compel them to adopt a process-based approach.

b Customer value creation process

The customer value creation process is based on the main flow (C Fig. 1), i.e. core business, such as product manufacturing, transport of persons or conveyance of a load. This process requires equipment in the form of machines and automated devices. This equipment can be confined to a single place, such as a factory, or else spread over extensive areas, as is the case for a water treatment and distribution plant. To work smoothly, the process requires additional flows such as electricity, air, water, gas and packaging.
A Fig. 1 Customer value creation process

The process engenders waste which must be collected, transported, treated and discarded.

1.2

The automation equipment

Automation equipment features five basic functions linked by power and control systems (C Fig. 2).

b Five basic functions

v Electrical power supply
Ensures the distribution of power to the power devicescapacity and control parts. It must be uninterrupted and protected in compliance with electrical installation and machines standards. This function is usually ensured by a circuit-breaker or fuse holder switch.

v Power control
Controls loads driven by the automatic device, either a contactor is used as a direct on line starter or an electronic controller is used to graduate the power supply of a motor or heater.

v Dialogue
A Fig. 2 Five basic functions

Commonly named man-machine interface, it is the link between the operator and the machine. It is function is to give orders and monitor the status of the process Control is made by push buttons, keyboards and touch screens and viewed through indicator lights, illuminated indicator banks and screens.

v Data processing
The software, part of the automation equipment, fusing the orders given by the operator and the process status measurements is the brain of the equipment. It controls the preactuators and sends information when and where required. The automation engineer has a wide range of options, from the simplest (as a set of push buttons directly controlling a contactor), through programmable logic systems to a collaborative link between the automated devices and computers. Today as simple low-cost automated devices are available, relay diagrams have practically disappeared.

1. Automation solution guide

1.2

The automation equipment

v Data acquisition
Data acquisition is mandatory to send feedback is to the controller or the PLC. Due to technological progress most of all physical value can now be detected or measured.

b The equipment must satisfy the external constraints

- to ensure the safety of the people and the production tools, - to respect the requirements of the environment such as the temperature, the shock protection, dust or environments aggressive.

b Power links
These are the connections between parts and include cables, busbars, connectors and mechanical protection such as ducts and shields. Current values range from a few to several thousand amperes. They must be tailored to cover electrodynamic and mechanical stress as well as heat stress.

b Control links
These are used to drive and control the automated devices. Conventional cabling systems with separate wires are gradually being replaced by ready-made connections with connectors and communication buses.

b Lifecycle of an automated equipment

An equipment is designed, then used and maintained throughout its lifecycle. This lifecycle depends on the users and their needs, the customers requirements and external obligations (laws, standards, etc.). The steps are as follows: - definition of the machine or process by the customer, - choice of automation equipment, - component supply, - commissioning, tests, - operation, - maintenance, - dismantling, recycling, destruction.

b Cost of an equipment
Cost reduction is an issue at every level during the choice and decisionmaking process. Its tightly bound with the customer needs. Though this guide only describes the technical aspects, it has been written with costeffectiveness in mind.

b Evolution of user needs and market pressure

Over the last few years, the automated device market has been subject to great economic and technological pressure. The main customer priorities are now: - shorten time to market, - expand the offer through flexible design so that new products can be marketed without having to overhaul the entire offer, - expand the offer through customisation, - cost reduction. This situation has created new needs: - reduction of development time, - reduction of complexity, - greater flexibility in particular when manufacturers have to change series, - gathering information for production management and maintenance (cost reduction, down times, etc.).

1. Automation solution guide

1.2 1.3

The automation equipment Automation architectures

To meet these requirements, an offer for reliable and powerful products must include ready-to-use architectures enabling intermediate players such as systems integrators and OEMs to specify and build the perfect solution for any end user. The figure 3 illustrates the relationship between market players and Schneider Electric offer.

A Fig. 3

Automatism market players

Architectures add value to the intermediate players, starting with the retailer or wholesaler, panel builder, machine installer or manufacturer. It is a global approach that enables them to respond more reliably, exactly and faster to end customers in different industries such as food, infrastructure or building.

1.3

Automation architectures
In the late 1990s, the conventional prioritised approach both in manufacturing processes (CIM: Computer Integrated Manufacturing) and in continuous processes (PWS: Plant Wide Systems) gave way to a decentralised approach. Automated functions were implemented as close as possible to the process (see the definition of these terms in the software section.) The development of web processes based on Ethernet and the TCP/IP protocol began to penetrate complex automated systems. These gradually split up and were integrated into other functions, thus giving rise to smart devices. This architecture made it possible to have transparent interconnection between the control systems and IT management tools (MES, ERP). At the same time, the components (actuators, speed controllers, sensors, input/output devices, etc.) gradually evolved into smart devices by integrating programming and communication features.

b Smart devices
These include nano-automated devices, automated cells (such as Power Logic, Sepam, Dialpact, etc.) and components with a regulating function, such as speed controllers. These products are smart enough to manage process functions locally and to interact with each other. Transparent communication means that tasks can be reconfigured and diagnoses made these possibilities are perfectly in line with the web process (individual addressing, information formatted to be ready to use, information provider management). The product line of smart devices products are systematically plug and play for power controllers, control bus and sensors. This approach means equipment can be replaced quickly and easily in the event of failure.

1. Automation solution guide

1.3

Automation architectures

The integration of browsers into keyboard and screen systems, radio controls and other MMIs has accelerated deployment of web technologies right up to the component level (see chapter 9 for explanations of connection and classes). The integration of control functions into smart devices has reduced the data flow on networks, thereby lowering costs, reducing the power of the automated devices and speeding up response times. There is less need for synchronisation because the smart devices process locally.

b Networks
At the same time, networks have been widely accepted and have converged on a limited number of standards which cover 80% of applications. There are many options open to designers (CANopen, AS-Interface, Profibus, DeviceNet, etc.) but the trend is towards a standard single network. In this framework, Ethernet, which has already won over the industrial computerisation sector, can also address needs for ground buses. A great many elements are now directly network-connectable. This is the result of the combined effects of web-technology distribution, rationalisation of communication standards, the sharp drop in the price of information technology and the integration of electronics into electro-mechanical components. These developments have led to the definition of field buses adapted to communication between components and automated devices such as Modbus, CANopen, AS-Interface, Device Net, Interbus S, Profibus, Fip, etc. The increasing need for exchange prompts customers to give priority to the choice of network ahead of automated equipment.

b Software and development tools

Programming tools have greatly expanded, from software dependent on hardware platforms to purely functional software downloaded onto a variety of hardware configurations. Communication between components is generated automatically. The information the programs produce is accessed by a unifying tool and shares a common distributed database, which considerably cuts down on the time taken to capture information (parameters, variables, etc.). So far, industrial automated device programming language concepts have not changed, with practically all suppliers promoting offers based on the IEC 61131-3 standard, sometimes enhanced by tools supporting collaborative control. Future improvements mainly concern the information generated by products designed to: - automatically generate the automated device configuration and input/output naming, - import and export functions to and from the automated devices software and the components software, - integrate electrical diagrams into diagnostics tools, - generate a common database, even for a simple configuration, - offer total transparency, - offer a single ergonomics which can be learnt once and for all for several uses. Software is an obligatory ingredient of widely different products and is used not only for programming, but also for configuration, parameter setting and diagnosis. These separate features can be included in the same program.

1. Automation solution guide

1.4 Architecture definition

1.4

Architecture definition

An architecture is designed to integrate, interface and coordinate the automated functions required for a machine or process with the object of productivity and environmental safety. A limited number of architectures can meet most automation requirements. To keep matters simple, Schneider Electric proposes to classify architectures on the basis of two structure levels (C Fig. 4): - functional integration based on the number of automation panels or enclosures, - the number of automated control functions, i.e. the number of control units in e.g. an automated device.

A Fig. 4

Type of architectures

These architectures are explained and illustrated in the following paragraphs.

b All in one device

The most compact structure, with all the functions in a single product, this architecture can range from the simplest to the most complex as illustrated in the two examples below.

v Remote controlled sliding door (C Fig. 6)

This only has a few functions (C Fig. 5), the control being limited to direct command of the power controller by the sensor and the dialogue to two buttons. The power controller also includes the power supply and the protection of the power circuit.
A Fig. 5

Simple architecture "All in on device"

A Fig. 6

Remote controlled sliding door

1. Automation solution guide

1.4

Architecture definition

v Conveyor system section (C Fig. 8)

Power control dialog, processing and detection are integrated into the speed controller (C Fig. 7). The other automated parts are linked via a communication bus. The power supply requires an electrical distribution panel covering all the automated equipment in the system.

A Fig. 8

Section of a conveyor system driven by an ATV71 with an integrated controller card

A Fig. 7

All in One device complex architecture

b All in one panel

This is the most common architecture (C Fig. 9), with the automated functions centralised in a single place which, depending on the case, is a single enclosure or built into the machine and has a single control function (application examples fig. 10,11,12).
A Fig. 10 LGP pump

A Fig. 11

Textile inspection machine

A Fig. 9

"All in one panel" architecture

A Fig. 12

Packaging machine

1. Automation solution guide

1.4

Architecture definition

b Distributed peripheral (C Fig. 13)

This architecture has a single central automated device to drive several automated distribution panels. It is suited to plant-wide machines and procedures and modular machines (C Fig. 14). The link is controlled by a ground bus. The power supply is centralised and often includes the parts for controlling and operating the safety system.

A Fig. 14

Industrial bakery machine

A Fig. 13

"Distributed peripheral" architecture

b Collaborative control
Several machines or parts of a procedure have their own controllers (C Fig. 15). They are linked together and collaborate in operating the system. This architecture is designed for large procedures such as in the petrochemical and steel industries or for infrastructures such as airports or water treatment plants (C Fig.16).

A Fig. 16

Water treatment

A Fig. 15 10

Collaborative control architecture

1. Automation solution guide

1.5

1.5

Choice of automated equipment

Choice of automated equipment

b Architecture implementation
We propose to help the customer by addressing their problem to guide them and optimise their choice of architecture and the products and services it will include. This process starts by ascertaining the customers needs and structuring questions as we shall describe. To make it easier to choose, Schneider Electric has optimised a number of variants based on the most common architectures. The first involves compact applications where the automated devices are grouped into an all-in-one panel. The second relates to procedure-distributed applications. The automated devices are divided up into several panels known as distributed peripherals. The other two (All in One Device and Collaborative Control) are not left out, but are presented differently. The all-in-one device is comparable to a single device and is treated as such. The collaborative control structure mainly involves data exchange between devices and is described in the section on links and exchanges. Its details are in the sections on automated devices and software.

b Choices offered by Schneider Electric

Both architecture concepts above can be implemented in many ways. To make it easier for the customer to choose, Schneider Electric has opted for a total of 10 possible implementations to offer optimal combinations. To prevent any confusion between the architecture concepts described above and the practical solutions Schneider Electric proposes, the latter will be referred to as preferred implementations. The table (C Fig. 17) below shows a summary of this approach.

A Fig. 17

Choice of Schneider Electric implementations

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1. Automation solution guide

1.5

Choice of automated equipment

b Preferred implementations
These implementations are the result of an optimization between the expressed needs and technologies available. The table (C Fig. 18) below shows a summary of them; they are described in greater detail in the documents provided by Schneider Electric.

A Fig. 18

Preferred implementations characteristics (refer to fig 5 to 11)

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1. Automation solution guide

1.5

Choice of automated equipment

b Choice of a preferred implementation

The solution approach to these implementations, which includes all the customers requirements, has many advantages: - simplified choice of automation systems, - peace of mind and confidence for the user because the devices are interoperable and performance levels are guaranteed, - once the implementation is chosen, the customer will have an adequately precise framework, alongside the catalogue and specific guides, to select the requisite automated functions and devices, - commissioning is facilitated by the work completed upstream. The table (C Fig. 19) below summarises the proposed approach:

A Fig. 19

Step by step approach for automatism choice

To assist customers choice, Schneider Electric has drawn up a complete guide with questions divided into four themes given the mnemonic of PICCS (Performance, Installation, Constraints, Cost, Size). An example is given (C Fig. 20 and 21) below. For all the implementations available, please refer to the catalogues. Here we are just illustrating the approach with examples.

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1. Automation solution guide

1.5

Choice of automated equipment

A Fig. 20

Guide for compact architectures

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1. Automation solution guide

1.5

Choice of automated equipment

A Fig. 21

Guide for distributed architectures

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1. Automation solution guide

1.5

Choice of automated equipment

We shall take three different applications and ascertain the most suitable architecture(s) for each of them.

v Tower crane
Notwithstanding its apparent simplicity, this machine (C Fig. 22) has to comply with stringent safety and environmental standards. Market competition forces manufacturers to consider the cost of every element. The features of this type of crane are: - power of the installation from 10 kW to 115 kW depending on the load to hoist (2 to 350 metric tons), - hoisting, rotation, trolleying and translation are driven by three-phase AC motors with two or three gears or AC drives. Braking is mechanical or electric, - the system requires about a dozen of sensors and the man-machine interface can be in the cabin or remote-controlled. The choice of implementation naturally focuses on an optimised compact system in a single panel at the basement of the crane. The highlighted colour coding in the selection table above shows the options at a glance (C Fig. 23).

A Fig. 22

Tower crane

A Fig. 23

Implementation choice for a tower crane

The Simple Compact is eliminated because its options are too limited. Both Optimised Compact and Evolutive Optimised Compact are suitable (C Fig. 24 and 25). The latter is even more suitable if the machine is a modular design or if remote maintenance is required.

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1. Automation solution guide

1.5

Choice of automated equipment

The choice of components naturally depends on the customers constraints and those of the chosen implementation. The figures below illustrate both possible implementations:

A Fig. 24

Compact optimised solution

A Fig. 25

Evolutive optimised compact solution

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1. Automation solution guide

1.5

Choice of automated equipment

The components are described in detail in the following sections.

v Conveyors and revolving tables

This kind of unit is very common in the manufacturing industry (C Fig. 26 and 27). The type of machine greatly depends on the surroundings. Its output has to be adjusted to the product and it is controlled by upstream and downstream automation. One automated device will control several sections in a conveyor and each element will have one or more panels. The main features are: - low power installation, - medium performance requirements, - per section, 2 to 10 three-phase AC motors with AC drives, - 10 to 50 inputs/outputs, - interface by keyboard and display, - real-time knowledge of the type and number of products conveyed. Since there are several linked equipments, the choice should focus on a distributed architecture. The selection table highlights the best solutions (C Fig. 28). The ASI bus one is a bit restricted because of the difficulties in speed control and the Ethernet one, except in some specific cases, is likely to be too expensive.

A Fig. 26

Revolving table

A Fig. 27

Conveyor

A Fig. 28

Conveying system choice

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1. Automation solution guide

1.5

Choice of automated equipment

This leaves the two CANopen field bus solutions. The first, which is more economical (C Fig. 29), ensures the basic requisite functions and the second (C Fig. 30) ensures transparency and synchronisation with automated devices outside the section involved. It is also easy to upgrade: a new configuration can be downloaded whenever a series is changed and so forth.

v Electrical diagram

A Fig. 29

Optimised CANopen solution

A Fig. 30

CANopen solution

v Drinking water supply

This example (C Fig. 31) illustrates part of an infrastructure for water treatment and distribution. It consists of a set of units spread over a territorial area. This kind of application must be standalone and ensure a continuous supply. Customers give great attention to supervision and maintenance of the installation. The features of the station are: - 4 pumps of 7.5 kW with AC drives, - a dozen of sensors (pressure, output, etc.), - an automated device to control pump sequencing and communication, - remote supervision of the installation.

A Fig. 31

Water treatment pumping station

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1. Automation solution guide

1.5

Choice of automated equipment

The choice will focus on a distributed implementation. The table (C Fig. 32) below shows the best one. The most suitable implementation is the Ethernet one (C Fig. 33 and 34), ensuring total transparency in the installation. The ASI bus is limited by its low data exchange capacity. The CANopen ones can be used with a modem but their possibilities are still restricted.

A Fig. 32

Water treatment pumping station architeture choice

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1. Automation solution guide

1.5

Choice of automated equipment

A Fig. 33

Solution 1 from a PLC

A Fig. 34

Solution 2 from a speed drive

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